Induction heating extension cables including control conductors

ABSTRACT

Induction heating extension cables including control conductors are disclosed. An example cable assembly includes: a first plurality of conductors in a Litz cable arrangement; an outer protective layer configured to protect the plurality of conductors from physical damage; and a second plurality of conductors that are electrically isolated from the first plurality of conductors and are protected by the outer protective layer from physical damage.

RELATED APPLICATIONS

This patent is a continuation-in-part of U.S. patent application Ser.No. 15/869,220, filed Jan. 12, 2018, entitled “INDUCTION HEATINGEXTENSION CABLES INCLUDING CONTROL CONDUCTORS,” which claims priority toU.S. Provisional Patent Application Ser. No. 62/447,161, filed Jan. 17,2017, entitled “INDUCTION HEATING EXTENSION CABLES INCLUDING CONTROLCONDUCTORS.” The entireties of U.S. Provisional Patent Application Ser.No. 62/447,161 is incorporated herein by reference.

BACKGROUND

Induction heating of workpieces to be welded, such as pipe, ofteninvolves arranging a fixture and/or one or more conductive cables inproximity to the workpiece. The power supply that provides inductionheating power may be located a substantial distance from the workpieceand/or the fixture, such that measuring heating parameters directly atthe power supply is not feasible.

SUMMARY

Induction heating extension cables including control conductors aredisclosed, substantially as illustrated by and described in connectionwith at least one of the figures, as set forth more completely in theclaims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a block diagram of an example induction heating systemincluding a cable assembly constructed in accordance with aspects ofthis disclosure.

FIG. 1B is a block diagram of another example induction heating system,in accordance with aspects of this disclosure.

FIG. 2 is an example implementation of the cable assembly of FIGS. 1Aand/or 1B.

The figures are not necessarily to scale. Where appropriate, similar oridentical reference numbers are used to refer to similar or identicalcomponents.

DETAILED DESCRIPTION

Induction heating extension cables deliver induction heating currentbetween an induction heating power supply (e.g., a power supplyproducing and/or converting induction heating currents) and an inductionheating cable (e.g., a cable that is positioned proximate a workpiecesuch that the induction heating currents induce eddy currents within theworkpiece). Induction heating extension cables may have the inductionheating current-carrying conductors tightly coupled to reduce (e.g.,minimize or eliminate) leakage and improve efficiency.

In contrast with conventional cables, disclosed example extension cablesinclude an additional control cable that transfers data and/or power andthat is contained within the outer protective layer of the extensioncable (e.g., is not exterior to the extension cable). Disclosed exampleextension cables couple an induction heating power supply to a remotedevice, which may be located near the workpiece, to exchange data withthe remote device and/or provide power to the remote device.Additionally, disclosed examples may omit electrical isolation measuresthat may be required when the data is electrically coupled to high-powerheating conductors, while being protected by the relatively tough outerjacket or protective layer of the extension cable from physical damagethat may occur in a welding-type environment.

Disclosed example cable assemblies include: a first plurality ofconductors in a Litz cable arrangement, an outer protective layerconfigured to protect the first plurality of conductors from physicaldamage, and a second plurality of conductors that are electricallyisolated from the first plurality of conductors and are protected by theouter protective layer from physical damage.

In some example cable assemblies, the second plurality of conductorsinclude a twisted pair of wires. In some example cable assemblies, thesecond plurality of conductors include coaxial conductors. Some examplecable assemblies further include a coupler to couple the first pluralityof conductors to an induction heating cable and to couple the secondplurality of conductors to an induction heating accessory. In some suchexamples, the second plurality of conductors conduct at least one ofpower or data between the induction heating accessory and an inductionheating power supply.

In some examples, the first plurality of conductors are configured toconduct induction heating current. In some examples, the first pluralityof conductors have a total cross-sectional area of at least 8.37 squaremillimeters, exclusive of electrical insulation. Some example cableassemblies further include a coupler to couple the first plurality ofconductors to an induction heating power supply and to couple the secondplurality of conductors to the induction heating power supply. In somesuch examples, the coupler couples the first plurality of conductors topower connectors of the induction heating power supply. In someexamples, the coupler couples the second plurality of conductors to acommunication connector of the induction heating power supply.

Disclosed example induction heating systems include an induction heatingpower supply, a monitoring device remote from the induction heatingpower supply, and a cable assembly. The cable assembly includes a firstplurality of conductors in a Litz cable arrangement, an outer protectivelayer configured to protect the first plurality of conductors fromphysical damage, and a second plurality of conductors that areelectrically isolated from the first plurality of conductors and areprotected by the outer protective layer from physical damage.

In some examples, the second plurality of conductors comprise a twistedpair of wires. In some examples, the second plurality of conductorscomprise coaxial conductors. Some example induction heating systemsfurther include a coupler to couple the first plurality of conductors toan induction heating cable and to couple the second plurality ofconductors to the monitoring device. In some such examples, the secondplurality of conductors conduct at least one of power or data betweenthe monitoring device and the induction heating power supply.

In some example induction heating systems, the first plurality ofconductors conduct induction heating current. In some examples, thefirst plurality of conductors have a total cross-sectional area of atleast 8.37 square millimeters, exclusive of electrical insulation. Someexample induction heating systems further include a coupler to couplethe first plurality of conductors to the induction heating power supplyand to couple the second plurality of conductors to the inductionheating power supply. In some such examples, the coupler couples thefirst plurality of conductors to power connectors of the inductionheating power supply. In some examples, the coupler couples the secondplurality of conductors to a communication connector of the inductionheating power supply.

FIG. 1A is a block diagram of an example induction heating system 100including a cable assembly 102. The heating system 100 includes aninduction heating power supply 104 that provides heating power to aworkpiece 106 via the cable assembly 102 and an induction heating cable107. The system 100 further includes a induction heating monitor 108.The induction heating monitor 108 may be a monitoring device formonitoring the workpiece 106 and/or may be any other type of inductionheating accessory.

The cable assembly 102 includes an outer protective layer 110, multipleconductors 112 a, 112 b in a Litz configuration, and a second set of twoor more conductors 114. The Litz conductors 112 a, 112 b provide currentto the heating cable 107. When the heating cable 107 are arrangedproximate the workpiece 106 (e.g., wrapped around the workpiece 106,attached to a fixture configured to direct the current to the workpiece106), the power supply 104 and the heating cable 107 induce Eddycurrents into the workpiece 106 to inductively heat the workpiece 106.In some examples, each of the example Litz conductors 112 a, 112 b mayhave effective gauge equivalent to American Wire Gauge (AWG) 8 (e.g., atotal cross-sectional area of at least 8.37 square millimeters,exclusive of the electrical insulation of the Litz conductors) orlarger. In examples in which multiple Litz conductors are used toimplement each of the Litz conductors 112 a, 112 b, the combination ofLitz conductors used to implement each of the Litz conductors has aneffective gauge equivalent to AWG 8 or larger (e.g., multiple conductorsimplementing the Litz conductor 112 a have a combined totalcross-sectional area of at least 8.37 square millimeters, exclusive ofthe electrical insulation of the Litz conductors, and multipleconductors implementing the Litz conductor 112 b have a combined totalcross-sectional area of at least 8.37 square millimeters). In stillother examples, the combination of the Litz conductors 112 a, 112 b mayhave effective gauge equivalent to AWG 8 (e.g., each of the Litzconductors 112 a, 112 b may have a gauge equivalent less than AWG 8).

The second conductors 114 are contained within the outer protectivelayer 110 (e.g., an outer jacket) of the cable assembly 102, but iselectrically isolated from the Litz conductors 112 a, 112 b so as to beisolated from the relatively high currents and/or voltages. The exampleouter protective layer 110 may be constructed using, for example, athermoplastic polyester elastomer (e.g., Hytrel®), polyurethane and/orany other material and/or combination of materials that providesmechanical and electrical protection to the Litz conductors 112 a, 112 band the second conductors 114. The second conductors 114 may deliverpower to the induction heating monitor 108 and/or exchange data signalsbetween the power supply 104 and the induction heating monitor 108.Example implementations of the second conductors 114 include one or moretwisted pairs of conductors or one or more coaxial cables. Otherimplementations may also be used.

The example cable assembly 102 of FIG. 1A further includes a powersupply coupler 116 and a heating cable coupler 118. The power supplycoupler 116 couples the conductors 112 a, 112 b to power terminals 120a, 120 b (e.g., positive and negative terminals) of the inductionheating power supply 104 and/or couples the second conductors 114 to acommunications terminal 122 of the induction heating power supply 104.The power terminals 120 a, 120 b may be studs that transmit the heatingpower for heating the workpiece 106 via the induction heating cable 107.The example induction heating power supply 104 may exchange data and/orprovide power to the induction heating monitor 108 via thecommunications terminal 122. In some examples, the power terminals 120a, 120 b and the communications terminal 122 are integrated into thesame connector, to which the power supply coupler 116 may connect.

The heating cable coupler 118 couples the conductors 112 a, 112 b to theinduction heating cable 107. The heating cable coupler 118 also couplesthe conductors 114 to the induction heating monitor 108 via externalconductors 124. The external conductors 124 may be of the same type asthe conductors 114 within the cable assembly 102. For example, if theconductors 114 include twisted pairs of wires, the external conductors124 may also be twisted pairs of wires. The external conductors 124 maybe replaceable so that the appropriate length of external conductors 124can be used to position the induction heating monitor 108 in a desiredlocation.

The example induction heating monitor 108 communicates with theinduction heating power supply 104 via the conductors 114 of the cableassembly 102. As mentioned above, the conductors 114 are electricallyisolated from the conductors 112 a, 112 b that carry the inductionheating power, and the conductors 114 and the conductors 112 a, 112 bare contained within an outer protective layer 110 of the cable assembly102. In the example of FIG. 1A, the induction heating monitor 108communicates and/or receives power via the conductors 114 within anextension cable. However, the conductors 114 may also be included atleast partially within the heating cable 107.

The induction heating monitor 108 includes a communications circuit 126,a control circuit 128, a data collection circuit 130, a power circuit132, an energy storage device 134, a user interface 136, and sensorinterface(s) 138. The example communications circuit 126 includes atransmitter circuit 140 and a receiver circuit 142.

The example transmitter circuit 140 transmits the induction heating datato the induction heating power supply 104 via the conductors 114 via theexternal conductors 124 and the heating cable coupler 118. The examplereceiver circuit 142 may receive data from the induction heating powersupply 104. The induction heating power supply 104 may include similarcommunication circuitry, including transmitter circuitry and/or receivercircuitry, to receive induction heating data and/or transmitconfiguration data to the induction heating monitor 108. In someexamples, the induction heating power supply 104 modifies an inductionheating output (e.g., induction heating power, etc.) based on theinduction heating data received from the induction heating monitor 108via the conductors 114.

The transmitter circuit 140 frames induction heating data fortransmission via the conductors 114. The induction heating data may begenerated from sensor data collected by one or more sensors 144 via thesensor interface(s) 138 and/or the data collection circuit 130. The datacollection circuit 130 may include sensor digitizer(s) 146 to digitizedata received from the sensor(s) 144. The induction heating data may beconverted to digital data via the sensor digitizer 146 and/or input by auser or operator via the user interface 136.

The example sensor(s) 144 may include a temperature sensor (e.g., athermocouple, a thermistor, a resistive temperature device, an infraredsensor, a semiconductor-based temperature sensor, etc.), a coolantpressure sensor, or a coolant flow sensor, and/or a location sensor.Example induction heating data includes one or more of an ambienttemperature at the workpiece 106 being heated with the induction heatingcable 107, a temperature of the induction heating cable 107, atemperature of a blanket in contact with the induction heating cable107, a temperature of the workpiece 106, a measurement of currentflowing through the induction heating cable 107, a voltage measurementof a voltage at the induction heating cable 107 (e.g., a voltage acrossthe portion of the induction heating cable 107 inductively coupled tothe workpiece 106), an error signal, a temperature of coolant flowingthrough the induction heating cable 107, a coolant pressure, a coolantflow rate, a workpiece identifier, an induction heating cableidentifier, an operator identifier, date information, time information,geographic information, a cable fixture identifier, and/or any type ofoperator or user input entered at the induction heating monitor 108.

The power circuit 132 extracts power from the conductors 114, 124, whichmay be multiplexed with data signals. The power circuit 132 providespower to the data collection circuit 130, the sensors 144 (e.g., via thesensor interface(s) 138), the control circuit 128, the user interface136, and/or the communications circuit 126. Additionally oralternatively, the power circuit may charge the energy storage device134. The example energy storage device 134 provides power to the datacollection circuit 130, the sensors 144 (e.g., via the sensorinterface(s) 138), the control circuit 128, the user interface 136,and/or the communications circuit 126 when the power circuit 132 is notcapable of powering the components. The example energy storage device134 may include one or more batteries, one or more capacitors, and/orany other type of energy storage device.

The example user interface 136 may include any type(s) of user interfacedevices, such as selection buttons, switches, dials, number pads,touchscreens, and/or any other type of user interface device.

FIG. 1B is a block diagram of another example induction heating system150. The induction heating system 150 of FIG. 1B is similar to theinduction heating system 100 of FIG. 1A, and includes the cable assembly102, the induction heating power supply 104, the workpiece 106, theinduction heating cable 107, the induction heating monitor 108, theouter protective layer 110, the conductors 112 a, 112 b in the Litzconfiguration, the second set of two or more conductors 114, the powersupply coupler 116, the power terminals 120 a, 120 b, and thecommunications terminal 122.

In contrast with the example system 100 of FIG. 1A, the example system150 couples the cable assembly 102 to the induction heating monitor 108instead of a heating cable coupler 118. The example induction heatingmonitor 108 receives the power and/or data via the second conductors 114(e.g., by terminating the second conductors 114). The induction heatingmonitor 108 of FIG. 1B passes the heating power from the conductors 112a, 112 b through to the heating cable 107. In some examples, theinduction heating monitor 108 may include connectors and/or terminationsfor the conductors 112 a, 112 b and for the heating cable 107, andinclude passthrough conductors to connect the conductors 112 a, 112 band the heating cable 107.

The example induction heating monitor 108 of FIG. 1B includes thecommunications circuit 126, the control circuit 128, the data collectioncircuit 130, the power circuit 132, the energy storage device 134, theuser interface 136, and the sensor interface(s) 138. The inductionheating monitor 108 collects induction heating data from one or moresensor(s) 144.

While example couplers 116, 118 are disclosed, the example cableassembly 102 may be coupled to the induction heating power supply 104,the heating cable 107, and/or the induction heating monitor 108 usingany combination and/or types of couplers and/or hard wiring.

FIG. 2 is an example implementation of the cable assembly 102 of FIGS.1A and/or 1B. The example cable assembly 102 includes four Litz wirebundles 202, two conductors 204 arranged in a twisted pairconfiguration, an outer jacket 206, and an internal wrap 208. Each ofthe Litz wire bundles 202 and the conductors 204 include an additionaljacket 210, which may be constructed of a thermoplastic elastomer (TPE).The example outer jacket 206 is constructed of a thermoplastic polyesterelastomer (e.g., Hytrel®), polyurethane and/or any other material and/orcombination of materials that provides mechanical and electricalprotection to the Litz wire bundles 202 and the conductors 204. Theinternal wrap 208 may be constructed using polytetrafluoroethylene(PTFE) tape.

As shown in FIG. 2 , the outer jacket 206 provides an outer protectivelayer that protects the Litz wire bundles 202 and the twisted pairconductors 204 from physical damage.

As utilized herein, “and/or” means any one or more of the items in thelist joined by “and/or”. As an example, “x and/or y” means any elementof the three-element set {(x), (y), (x,y)}. In other words, “x and/or y”means “one or both of x and y”. As another example, “x, y, and/or z”means any element of the seven-element set {(x), (y), (z), (x,y), (x,z),(y,z), (x,y,z)}. In other words, “x, y and/or z” means “one or more ofx, y and z”. As utilized herein, the term “exemplary” means serving as anon-limiting example, instance, or illustration. As utilized herein, theterms “e.g.,” and “for example” set off lists of one or morenon-limiting examples, instances, or illustrations.

While the present method and/or system has been described with referenceto certain implementations, it will be understood by those skilled inthe art that various changes may be made and equivalents may besubstituted without departing from the scope of the present methodand/or system. In addition, many modifications may be made to adapt aparticular situation or material to the teachings of the presentdisclosure without departing from its scope. For example, blocks and/orcomponents of disclosed examples may be combined, divided, re-arranged,and/or otherwise modified. Therefore, it is intended that the presentmethod and/or system not be limited to the particular implementationsdisclosed, but that the present method and/or system will include allimplementations falling within the scope of the appended claims, bothliterally and under the doctrine of equivalents.

1-20. (canceled)
 21. An induction heating monitoring system, comprising:an induction heating monitor comprising a data collection circuitconfigured to collect induction heating data associated with aninduction heating operation performed using the induction heating powersupply; and a cable data coupler configured to: pass through inductionheating power received via one or more first conductors within an outerjacket of an induction heating cable; and couple the induction heatingmonitor to a second one or more conductors within the outer jacket ofthe induction heating cable to communicate the induction heating data tothe induction heating power supply.
 22. The apparatus as defined inclaim 21, wherein the induction heating cable comprises an extensioncable configured to conduct current between the induction heating powersupply and an induction heating coil.
 23. The apparatus as defined inclaim 21, wherein the induction heating monitor further comprises acommunication circuit configured to communicate via the one or moresecond conductors.
 24. The apparatus as defined in claim 23, wherein thecommunication circuit comprises at least one of: a transmitter circuitconfigured to transmit the induction heating data to the inductionheating power supply; or a receiver circuit configured to receiveconfiguration data from the induction heating power supply.
 25. Theapparatus as defined in claim 23, further comprising a power circuitconfigured to receive power via the one or more first conductors and toprovide power to the data collection circuit.
 26. The apparatus asdefined in claim 23, further comprising a sensor interface configured toreceive data from a sensor.
 27. The apparatus as defined in claim 26,wherein the data collection circuit further comprises a sensor digitizerconfigured to digitize the data received from the sensor.
 28. Theapparatus as defined in claim 26, wherein the sensor interface isconfigured to receive the data from at least one of a thermocouple, athermistor, a resistance temperature detector, an infrared sensor, asemiconductor-based temperature sensor, a pressure sensor, a flowsensor, or a location sensor.
 29. The apparatus as defined in claim 21,wherein the cable data coupler comprising first terminations configuredto be coupled to the one or more first conductors and secondterminations coupled to the first terminations to be coupled to at leastone of an induction heating extension cable or an induction heatingblanket.
 30. The apparatus as defined in claim 21, wherein the one ormore first conductors comprise Litz wire.
 31. An induction heatingsystem, comprising: an induction heating power supply; a cable assembly,comprising: a first plurality of conductors in a Litz cable arrangement;an outer protective layer configured to protect the first plurality ofconductors from physical damage; and a second plurality of conductorsthat are electrically isolated from the first plurality of conductorsand are protected by the outer protective layer from physical damage; aninduction heating monitor comprising a data collection circuitconfigured to collect induction heating data associated with aninduction heating operation performed using the induction heating powersupply; and a cable data coupler configured to: pass through inductionheating power received via the first plurality of conductors within anouter jacket of an induction heating cable; and couple the inductionheating monitor to the second plurality of conductors within the outerjacket of the induction heating cable to communicate the inductionheating data to the induction heating power supply.
 32. The inductionheating system as defined in claim 31, wherein the induction heatingcable comprises an extension cable configured to conduct current betweenthe induction heating power supply and an induction heating coil. 33.The induction heating system as defined in claim 31, wherein theinduction heating monitor further comprises a communication circuitconfigured to communicate via the second plurality of conductors. 34.The induction heating system as defined in claim 33, further comprisinga power circuit configured to receive power via the second plurality ofconductors and to provide power to the data collection circuit.
 35. Theinduction heating system as defined in claim 33, further comprising asensor, the data collection circuit comprising a sensor interfaceconfigured to receive data from a sensor.
 36. The induction heatingsystem as defined in claim 35, wherein the sensor interface isconfigured to receive the data from at least one of a thermocouple, athermistor, a resistance temperature detector, a semiconductor-basedtemperature sensor, a pressure sensor, a flow sensor, or a locationsensor.
 37. The induction heating system as defined in claim 35, whereinthe data collection circuit further comprises a sensor digitizerconfigured to digitize the data received from the sensor.
 38. Theinduction heating system as defined in claim 33, wherein the inductionheating power supply is configured to modify an induction heating outputbased on the induction heating data.
 39. The induction heating system asdefined in claim 31, wherein the first plurality of conductors isconfigured to conduct induction heating current.
 40. The inductionheating system as defined in claim 31, wherein the second plurality ofconductors comprises at least one of a twisted pair of wires or acoaxial cable.